MAN ES’ subsidiary opens automated electrolyzer gigafactory in Hamburg

Electrolysis specialist Quest One, a subsidiary of MAN Energy Solutions (MAN ES), has opened a new “gigahub” for the serial and automated production of electrolysis stacks in Hamburg, Germany.

In the presence of more than 800 guests, including German Chancellor Olaf Scholz and Peter Tschentscher, First Mayor of Hamburg, Uwe Lauber, CEO of MAN ES, and Quest One’s CEO Robin von Plettenberg kicked off this “new phase” in the ramp-up of the hydrogen economy.

At the new site, the hydrogen technology specialist is starting the serial and automated production of so-called PEM electrolysis stacks for the production of green hydrogen. PEM electrolysis, which is based on proton exchange membrane (PEM) technology, is said to be one of the most important processes for industrially scaled hydrogen production from renewable energies.

MAN ES called the series production an important step towards making green hydrogen available in large quantities and thus becoming a reliable alternative to fossil fuels.

Lauber stated: “Today we are opening Europe’s most modern production plant in the hydrogen economy. MAN Energy Solutions and Quest One are thus making a substantial contribution to the establishment and industrialisation of sustainable future technologies in Germany and Europe. We are thus investing in the future of Germany as a business location and in the energy transition as a task for society as a whole. Because there is no alternative for a climate-neutral future. MAN Energy Solutions, as one of the oldest industrial companies in the world, will continue to work towards this goal.”

Scholz commented: “Today, Hamburg-Rahlstedt is sending out a signal. Until now, electrolysers have been made by hand. If the step towards automated production on an industrial scale is successful, the costs and time required for production will fall. Serial production should reduce the production time here in Rahlstedt by 75 percent. This is a real milestone for the rapid hydrogen ramp-up and shows what is possible in our country.”

At full capacity, the new “gigahub” is expected to enable the automated series production of PEM stacks with a potential total electrolysis capacity of over five gigawatts per year. To note, stacks are the technological centerpiece of electrolyzers and split water into oxygen and hydrogen with the help of renewable electricity.

According to MAN ES, the highly automated stack production takes place on two production lines: “Titan” with a linear transport system and “Gerd” with swivelling arm robots.

The company noted: “Many work steps that were previously carried out by hand are now automated which reduces the production time of a stack by around 75 per cent − they can now be produced in Hamburg in less than an hour. The automated production also increases the company’s efficiency and precision in manufacturing and optimising logistics processes, resulting in consistently high product quality and fast delivery times.”

Von Plettenberg said: “The hydrogen economy will change massively in the coming years and decades, and we will be dealing with volumes that are almost unimaginable today. Thus, the electrolysis industry will become one of the key industries of the future. With our gigahub, we are opening one of the most modern sites for PEM technology, development and production in the world here in Hamburg. However, this also emphasises that we want to become a leading player in the hydrogen economy. Our goal is to use our products to avoid one per cent of global greenhouse emissions by 2050.”

Tschentscher stressed: “The availability of green hydrogen is a crucial factor for the energy transition and the competitiveness of the German industry. The opening of the Quest One Gigahub is a milestone in this respect. Hamburg is becoming a leading hydrogen location in Germany. Together with our international energy partners, we are strengthening the Port of Hamburg as an important transshipment point for hydrogen in Europe.”

The automated stack production is part of the PEP.IN research project and was funded by the hydrogen lead project H2Giga of the German Federal Ministry of Education and Research (BMBF). As per MAN ES, the aim is to research innovative processes for the competitive and series production of PEM electrolysis stacks and electrolysers in Germany in order to make green hydrogen affordable and competitive.

As disclosed, the “gigahub” was built in just one and a half years on a site measuring over 26,000 square meters in Victoria Park, an industrial park in Hamburg, and sustainability played a central role in its development. Initially, around 200 employees will work here in the areas of production, development, testing and service. The site will also serve as a customer and training center.

With the opening of this production site, the company, formerly known as H-TEC SYSTEMS, changed its name and officially became Quest One.

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